{"id":4295,"date":"2022-05-05T06:41:46","date_gmt":"2022-05-05T13:41:46","guid":{"rendered":"https:\/\/blogs.solidworks.com\/delmiaworks\/?p=4295"},"modified":"2022-05-04T17:03:24","modified_gmt":"2022-05-05T00:03:24","slug":"how-to-optimize-production-capacity-and-scheduling","status":"publish","type":"post","link":"https:\/\/blogs.solidworks.com\/delmiaworks\/how-to-optimize-production-capacity-and-scheduling\/","title":{"rendered":"How To Optimize Production Capacity And Scheduling"},"content":{"rendered":"<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-4301 size-large\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1-615x297.jpg\" alt=\"How to Optimize Production Scheduling\" width=\"615\" height=\"297\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1-615x297.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1-300x145.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1-768x371.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1-728x352.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/APS-1440x696-1.jpg 1440w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>To help optimize production capacity and scheduling, manufacturers turn to integrated ERP systems to find new insights into how they can solve complex scheduling conflicts. When production management teams settle for &#8220;just good enough&#8221; scheduling decisions, everything from machine capacity to customer delivery dates suffers. Staying competitive in manufacturing means always striving to optimize production capacity and scheduling in real-time. And that needs to start by automating these two core production processes.<\/p>\n<h3><strong>Signs It&#8217;s Time To Optimize Production Capacity &amp; Scheduling\u00a0<\/strong><\/h3>\n<p>Scheduling production manually or with spreadsheets is a complex, calculation-intensive job. It can also lead to accidental errors or omissions that create shock waves across the shop floor, stopping production. Factoring in a diverse series of inputs, including demand forecasts, raw materials availability, tools and equipment availability, required delivery time, production rates, and more, requires an automated approach.<\/p>\n<p>Machinery capacity and availability determine a plant&#8217;s potential to produce revenue. Scheduling inefficiencies, unplanned downtime, and underutilized machine capacity can reduce a plant&#8217;s productivity by 25%, potentially leaving a typical business with $3 to $5 million a year in unrealized revenue.<\/p>\n<p>Sure signs a manufacturer&#8217;s facilities need to move away from manually-based scheduling and adopt a more automated approach to optimize production scheduling include:<\/p>\n<ul>\n<li>Increasing resource conflicts and challenges to meet production schedules and customer delivery dates.<\/li>\n<li>Work center capacity is increasingly underutilized, driving up operating costs and creating challenges in delivering products on time.<\/li>\n<li>Unplanned equipment downtime is causing bottlenecks on the plant floor and requires scheduling changes that take hours instead of minutes.<\/li>\n<li>Greater challenges assigning the best-trained production teams to the highest priority orders. Inexperienced production teams can lead to lower product quality and growing returns.<\/li>\n<li>Excessive rework caused by jobs running on under-performing equipment. One automotive parts manufacturer&#8217;s production orders had to be reworked seven times on average while being scheduled across production work centers. With a cost of $165 per order rework, not having automated scheduling with &#8220;runs-the best&#8221; capability costs $1,155 per order to cover the errors that could have been solved with better automation.<\/li>\n<\/ul>\n<h3><strong>How An Integrated Manufacturing ERP System Can Help\u00a0<\/strong><\/h3>\n<p>Knowing how efficient equipment capacity is being used across the shop floor directly impacts the plant&#8217;s ability to deliver revenue. Getting production capacity and scheduling right needs to start with an integrated manufacturing ERP system that can measure and manage production constraints. This includes knowing:<\/p>\n<ul>\n<li>What machines are available to do the work<\/li>\n<li>The current condition of shop floor equipment<\/li>\n<li>When raw material can be dispositioned<\/li>\n<li>Whether all machines are fine-tuned for the specific raw materials being used<\/li>\n<li>If tools and special equipment are available<\/li>\n<li>If the best possible production teams are available<\/li>\n<\/ul>\n<p>An integrated ERP system designed to optimize production scheduling reduces fire drills and ensures consistency and optimization to help drive revenue, with capabilities to:<\/p>\n<ul>\n<li><strong>Create an optimized schedule based on actual historical performance.<\/strong>\u00a0By automating production scheduling that analyzes historical production and performance data and demand forecasts, each day&#8217;s schedule is optimized for the given skill sets, tool capacity and function, fixture limitations, and work center capacity.<\/li>\n<li><strong>Perform &#8220;what-if&#8221; analyses to identify how tradeoffs in capacity and scheduling impact revenue.\u00a0<\/strong>When capacity planning, optimization, scheduling, MES, and financials share the same database, it is possible to perform what-if tradeoffs before committing resources to production. What-if analysis also shows the impact on each order&#8217;s costs, margins, and revenue. It gives manufacturers the freedom to choose the best possible approach to optimizing production in real-time.<\/li>\n<li><strong>Know Available-to-Promise (ATP) and Capable-To-Promise (CTP) for every order.<\/strong>\u00a0Including ATP and CTP on quotes and proposals is one of the most proven ways to win more sales. The manufacturer with a complete quote gives prospects all they need to make a purchasing decision that makes the most sales. The benefit of having comprehensive quotes sent to prospects that define when orders can ship is a strategy more manufacturers need to consider using.<\/li>\n<li><strong>Provide greater shop floor visibility, control, and proven gains in productivity.\u00a0<\/strong>Excelling at production scheduling starts by realizing manually-based spreadsheets and worksheets aren&#8217;t delivering the insights and visibility needed to become competitively stronger. An integrated ERP system\u00a0<em>can<\/em>\u00a0make any manufacturer stronger by automating scheduling that factors in all production variables (orders, raw materials, machine availability, and labor)\u2014optimizing a production schedule in minutes instead of hours.<\/li>\n<\/ul>\n<h3><strong>Conclusion\u00a0<\/strong><\/h3>\n<p>Having production capacity and scheduling share the same database as an integrated ERP system makes it more efficient to schedule production runs and special orders, reacting in real-time to unexpected events. It is also possible to minimize lost machine and labor hours and expedite orders with minimal disruption of normal production. Having analytics and tools for performing &#8220;what if&#8221; analysis also helps identify the best combination of teams, machinery, tools, raw material work instructions, and products to be produced given the constraints on a shop floor. It is time to compete with more insightful, real-time data. That is why optimizing production capacity and scheduling with an integrated manufacturing ERP is critical to succeeding in today&#8217;s competitive environment.<\/p>\n<p><a href=\"https:\/\/discover.3ds.com\/understanding-roi-manufacturing-erp\" target=\"_blank\" rel=\"noopener\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-4150 size-full\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/erp-value-whitepaper-ctav.jpg\" alt=\"Learn the values of an ERP system and how it can provide greater visibility of manufacturing costs.\" width=\"633\" height=\"290\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/erp-value-whitepaper-ctav.jpg 633w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/erp-value-whitepaper-ctav-300x137.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/17\/erp-value-whitepaper-ctav-615x282.jpg 615w\" sizes=\"auto, (max-width: 633px) 100vw, 633px\" \/><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>To help optimize production capacity and scheduling, manufacturers turn to integrated ERP systems to find new insights into how they can solve complex scheduling conflicts. When production management teams settle for &#8220;just good enough&#8221; scheduling decisions, everything from machine capacity<\/p>\n... <a href=\"https:\/\/blogs.solidworks.com\/delmiaworks\/how-to-optimize-production-capacity-and-scheduling\/\">Continued<\/a>","protected":false},"author":616,"featured_media":4301,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[25,27,29],"tags":[322,321,226,323],"class_list":["post-4295","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-all-posts","category-manufacturing-trends-and-news","category-erp-technology-and-automation","tag-manufacturing-capacity","tag-manufacturing-scheduling","tag-production-scheduling","tag-shop-floor-capacity","avhec_catgroup-all","avhec_catgroup-home"],"acf":[],"_links":{"self":[{"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/posts\/4295","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/users\/616"}],"replies":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/comments?post=4295"}],"version-history":[{"count":7,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/posts\/4295\/revisions"}],"predecessor-version":[{"id":4303,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/posts\/4295\/revisions\/4303"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/media\/4301"}],"wp:attachment":[{"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/media?parent=4295"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/categories?post=4295"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/blogs.solidworks.com\/delmiaworks\/wp-json\/wp\/v2\/tags?post=4295"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}